Packaging insert for protecting articles and the like

ABSTRACT

A packaging system for retaining an article therein is provided. The packaging system comprises a first flat sheet member foldable into a first container portion and a second flat sheet member foldable into a second container portion. The second container portion is moveable to a position adjacent the first container portion. The packaging system further comprises a first open area within the first container portion and a second open area within the second container portion. A retention mechanism releasably retains the article within the first container portion wherein the first open area and the second open area substantially surround the article.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] This invention relates generally to a packaging insert forprotecting articles and the like. More specifically, it is concernedwith a packaging insert having a sling type retention mechanism forretaining the articles within the packaging insert and a doubleprotective cell surrounding the articles.

[0003] 2. Description of the Prior Art

[0004] When articles are shipped from one location to another, it isnecessary to safely pack or crate the articles to inhibit damage to thearticles during transport and storage. Protective packaging inserts areoften used when an article to be packaged requires protection fromphysical shock, dust, dirt, and other contaminants. For example, whenshipping articles which are relatively fragile, it is often desirable topackage the articles inside a box to protect the articles from physicalimpacts to the box which can occur during loading, transit, andunloading. In addition, when shipping articles such as computercomponents, it is often desirable to protect those computer componentsfrom dust and dirt.

[0005] Additionally, in most cases, some additional structure is used tokeep an object within a box from moving uncontrollably in the box andthus incurring damage. Such additional structures include paper orplastic dunnage, structured plastic foams, and foam filled cushions,among others.

[0006] Unfortunately, most of the packaging inserts or structures of theprior art do not adequately retain the article within the packaginginsert and protect the article from physical impacts to the box in whichthe article is packaged. Furthermore, the complexity of assembling thepackaging inserts and packaging the article within the packaging insertsof the prior art and the box increases the material costs and the timerequired to pack the articles thereby directly substantially increasingthe cost for shipping the articles.

[0007] It is an object of the present invention, therefore, to provide apackaging insert for protecting articles and the like.

[0008] Another object of the present invention is to provide a packaginginsert having a sling type retention mechanism for retaining thearticles within the packaging insert.

[0009] Yet another object of the present invention is to provide apackaging insert having a double protective cell surrounding thearticles for protecting the articles from physical impacts to the box inwhich the articles is packaged.

[0010] Still another object of the present invention is to provide apackaging insert which is easy to manufacture, easy to construct, andeasy to disassemble.

[0011] Additional object, advantages and novel features of the inventionwill be set forth in part in the description and drawings which follow,and in part will become apparent to those skilled in the art uponexamination of the following or may be learned by practice of theinvention. The objects and advantages of the invention may be realizedand attained by means of the instrumentalities and combinationsparticularly pointed out in the appended claims.

SUMMARY

[0012] To achieve the foregoing and other objects and in accordance withthe purpose of the present invention as embodied and broadly describedherein, the present invention is directed to a packaging insert forprotecting articles and the like.

[0013] The present invention is a packaging system for retaining anarticle therein. The packaging system comprises a first flat sheetmember foldable into a first container portion and a second flat sheetmember foldable into a second container portion. The second containerportion is moveable to a position adjacent the first container portion.The packaging system further comprises a first open area within thefirst container portion and a second open area within the secondcontainer portion. A retention mechanism releasably retains the articlewithin the first container portion wherein the first open area and thesecond open area substantially surround the article.

[0014] The present invention further includes a packaging system forretaining an article therein. The packaging system comprises a flatsheet member having a plurality of panel members wherein the flat sheetmember is foldable into a first container portion and a second containerportion with the second container portion movable against the firstcontainer portion with the article being releasably secured within thefirst container portion.

[0015] The present invention further yet includes a method for retainingan article within a packaging system. The method comprises providing aflat sheet member, releasably securing the article to the flat sheetmember, folding the sheet member into a first container portion and asecond container portion with the article being secured within the firstcontainer portion, and moving the second container portion to a positionadjacent the first container portion.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016]FIG. 1 is a perspective view illustrating a packaging insert forprotecting articles and the like, constructed in accordance with thepresent invention, with the packaging insert being constructed prior toinsertion into a box;

[0017]FIG. 2 is another perspective view illustrating the packaginginsert for protecting articles and the like, constructed in accordancewith the present invention, with the packaging insert being constructedprior to insertion into the box;

[0018]FIG. 3 is a perspective view illustrating the packaging insert forprotecting articles and the like, constructed in accordance with thepresent invention, with the packaging insert being inserted into thebox;

[0019]FIG. 4 is a front view illustrating the constructed packaginginsert for protecting articles and the like as illustrated in FIG. 1,constructed in accordance with the present invention;

[0020]FIG. 5 is a top view illustrating the constructed packaging insertfor protecting articles and the like as illustrated in FIG. 1,constructed in accordance with the present invention;

[0021]FIG. 6 is a side view illustrating the constructed packaginginsert for protecting articles and the like as illustrated in FIG. 1,constructed in accordance with the present invention;

[0022]FIG. 7 is a front view illustrating the packaging insert forprotecting articles and the like, constructed in accordance with thepresent invention, prior to insertion of the article and construction ofthe packaging insert;

[0023]FIG. 8 is a back view illustrating the packaging insert forprotecting articles and the like as illustrated in FIG. 7, constructedin accordance with the present invention, prior to insertion of thearticle and construction of the packaging insert;

[0024]FIG. 9 is a front view illustrating the packaging insert forprotecting articles and the like, constructed in accordance with thepresent invention, with the article being inserted and the packaginginsert being partially constructed;

[0025]FIG. 10 is a side view illustrating the packaging insert forprotecting articles and the like as illustrated in FIG. 9, constructedin accordance with the present invention, with the article beinginserted and the packaging insert being partially constructed;

[0026]FIG. 11 is a side view illustrating the packaging insert forprotecting articles and the like, constructed in accordance with thepresent invention, during an additional step of constructing thepackaging insert;

[0027]FIG. 12 is a side view illustrating the packaging insert forprotecting articles and the like, constructed in accordance with thepresent invention, during an additional next step of constructing thepackaging insert;

[0028]FIG. 13 is a sectional view illustrating the packaging insert forprotecting articles and the like, constructed in accordance with thepresent invention, after complete construction of the packaging insert;

[0029]FIG. 14 is a perspective view illustrating multiple packaginginserts for protecting articles and the like, constructed in accordancewith the present invention, being inserted into the box;

[0030]FIG. 15 is a table illustrating various size and foldingcomputations for the packaging insert for protecting articles and thelike, constructed in accordance with the present invention; and

[0031]FIG. 16 is a side view illustrating a folding computation keydiagram for the table of FIG. 15.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0032] As illustrated in FIGS. 1-6, the present invention is a packagingsystem, indicated generally at 10, for protecting articles 12 and thelike within a box 14. The packaging system 10 of the present inventionis designed to provide maximum speed and simplicity for manuallypackaging a variety of variously shaped articles 12 for shipping anddisplay. Unlike conventional packaging systems that are specificallyconstructed for the shape and size of the article to be shipped, thepackaging system 10 of the present invention is self conforming to avery wide variety of article shapes or sizes with no customizationrequired or special handling of the packaging system 10 or the article12 to be packaged (see FIG. 6).

[0033] As illustrated in FIGS. 7 and 8, the packaging system 10 of thepresent invention is a flat sheet member 16 comprising a plurality ofpanels, namely, panel A, panel B, panel C, panel D, panel E, panel F,panel G, and panel H. Preferably, the flat sheet 16 is constructed froma single piece of dye cut corrugated cardboard. It should be noted,however, that while the flat sheet member 16 has been described as beingconstructed from a single piece of dye cut corrugated cardboard, it iswithin the scope of the present invention to construct the flat sheetmember 16 from multiple pieces or panels and/or from other suitablematerials including, but not limited to corrugated plastics, lightcomposites, etc.

[0034] The flat sheet member 16 further includes a first fold line Jbetween panel A and panel B, a second fold line K between panel B andpanel C, a third fold line L between panel C and panel D, and a fourthfold line M between panel D and panel E. Additionally, the flat sheetmember 16 includes a fifth fold line N formed in panel F, a sixth foldline O between panel F and panel G, a seventh fold line P formed inpanel H, and an eighth fold line Q formed between panel G and panel H.

[0035] Furthermore, the flat sheet 16 includes a first score line R isformed between panels A and B and panel H, a second score line S isformed between panel C and panel G, and a third score line T formedbetween panels D and E and panel F.

[0036] The packaging system 10 of the present invention further includesa stretchable film layer 18 mounted substantially over panels C and G.The stretchable film layer 18 wraps around the flat sheet member 16 andis attached to the back side of the flat sheet member 16, as illustratedin FIG. 8, by means of an adhesive 32 including, but not limited to,glue, tape or heat seal. It is within the scope of the present inventionto utilize any type of stretchable film layer 18 such as commonwarehouse grade stretchable wrap film layer having a thickness ofapproximately eight (8) mils or nine (9) mils or an expensivepolyurethane cast and extruded film layer that could be beneficiallyutilized for its stretch recovery memory capability.

[0037] The construction of the packaging system 10 of the presentinvention will now be described. A person skilled in the art willunderstand and realize that while one particular construction embodimentwill be described, other embodiments of construction of the packagingsystem 10 are within the scope of the present invention.

[0038] First, the article 12 to be packaged is inserted between thestretchable film layer 18 and the panel C of the flat sheet member 16.As illustrated in FIGS. 10 and 13, the stretchable film layer 18substantially conforms to the size and the shape of the article 12therein inserted. Next, as illustrated in FIGS. 7-10, the panel A isfolded along the fold line J to substantially ninety (90°) degreesrelative to the panel B and the panel B is folded along the fold line Kto substantially ninety (90°) degrees relative to the panel C. Then, thepanel E is folded along the fold line M to substantially ninety (90°)degrees relative to the panel D and the panel D is folded along the foldline L to substantially ninety (90°) degrees relative to the panel C.The panel A and the panel E include cooperating interlocking slots 28for releasably connecting the panel A to the panel E thereby creating afirst protective cell 20, as illustrated in FIG. 13, about the retainedarticle 12.

[0039] After constructing the first protective cell 20, the packagingsystem 10 is then positioned to rest on the bottom edges I of the panelsA, B, C, D, and E. Now in the opposite direction, or away from thestretchable film layer 18, as illustrated in FIGS. 7-10, the panel H isfolded along the fold line N to substantially ninety (90°) degrees andthe panel F is folded along the fold line O to substantially ninety(90°) degrees relative to the panel G. Next, in the opposite direction,or away from the stretchable film layer 18, the panel H is folded alongthe fold line P to substantially ninety (90°) degrees and panel H isfolded along the fold line Q to substantially ninety (90°) degreesrelative to the panel G. The panel F and the panel H include cooperatinginterlocking slots 30 for releasably connecting the panel F to the panelH thereby creating a second protective cell 22, as illustrated in FIG.13, about the retained article 12.

[0040] As illustrated in FIGS. 11-13, the second protective cell 22 isthen moved toward the first protective cell 20 until the panel G ispositioned against the panel C. The packaging system 10 includes a selfadjusting height flange 24 hingedly connected to the flat panel member16 and movable against the retained article 12. The self adjustingheight flange 24 provides strain relief for tall articles 12 by allowingthe stretchable film layer 18 to urge or pull the self adjusting heightflange 24 in a generally upward direction as the stretchable film layer18 becomes tighter from the movement of the second protective cell 22toward the first protective cell 24. Therefore, the self adjustingheight flange 24 adjusts the pressure and article height to securelyretain and protect the article 12 therein.

[0041] With the article 12 being retained and protected in the packagingsystem 10, as illustrated in FIG. 3, the packaging system 10 is insertedinto the shipping box 14 with the article 12 well protected by thepanels of the flat sheet member 16 and the air within the firstprotective cell 20 and the second protective cell 22. The front side ofthe article 12 has three panels of the flat sheet member 16 and thesubstantial air space of the first protective cell 20 between thearticle 12 and the outside and the back side of the article 12 has fivepanels of the flat sheet member 16 and the air space of the secondprotective cell 22.

[0042] If the outer box 14 receives a jarring impact, the panels of theflat sheet member 16 will flex and allow the protected articles 12 tomove on the panels and not transfer the impact through to the article12. To extract the article 12 from the packaging system 10, thepackaging system 10 is merely removed from the outer box 14 and unfoldedin the reverse order it was assembled. The packaging system 10 can thenbe re used if needed, even with a differently shaped article 12.Importantly, the article 12 will not be arbitrarily released from thepackaging system 10 when the packaging system 10 it is removed from thebox 14 because the article 12 remains captured inside the firstprotective cell 20.

[0043] Many variations are possible including containing a smallerarticle in a custom tray (not shown) before insertion into the packagingsystem 10 for static discharge protection. The correct minimum size fora packaging system 10 can be computed, as illustrated in FIGS. 15 and16. As illustrated in FIG. 14, the packaging system 10 can also be putinto master boxes because one packaging system 10 can be stacked next toor on top of another packaging system 10 still maintaining the integrityof the first protective cell 20 and the second protective cell 22.

[0044] The inventors of the present application believe that there is noconventional packaging system capable of protecting an article 12 aswell as the packaging system 10 of the present invention with so littleassembly effort or as cost effectively. The packaging system 10 uses aunique progressive leverage single folding flange 24 to secure thearticle 12 with a minimum amount of dexterity or training on the part ofthe user. The packaging system 10 uses the flexibility and stretch ofthe stretchable film layer 18 from which it is constructed, to “selfadjust” for the article 18 being packaged.

[0045] Additionally, the packaging system 10 of the present inventionuses a reverse mount wrap around application of the stretchable filmlayer 18 to achieve extreme reliability of the bond between the flatsheet member 16 substrate and the stretchable film layer 18. The reversemount wrap around becomes an integral part of the self adjusting heightflange 24 for odd or extra wide objects.

[0046] Furthermore, the packaging system 10 of the present inventionprovides protective air space on all sides of the packaged article 12and not a rigid substrate that rests directly against the side of theexternal container or box. The sling configuration of the packagingsystem 10 allows the packaging materials to absorb shocks and not thepackaged article 12. The packaging system 10 does not require expensiveor exotic materials for construction while maintaining a professionalhigh tech appearance.

[0047] The packaging system 10 of the present invention can be reused,even for a different sized article 12 than originally packaged. Becauseof the versatility of the packaging system 10, shippers need onlymaintain a very minimal packaging inventory and the packaging system 10stores flat until use thereby saving very significant amounts of storagespace and shipping and handling costs.

[0048] The packaging system 10 of the present invention further hasseveral large flat areas 26 (see FIG. 1) that can be used forpromotional displays integral to the packaging system 10. The packagingsystem 10 can be made to fit virtually any existing box size, whicheliminates the cost of a transition from older less effective packagingsystems.

[0049] The foregoing description of the preferred embodiments of thesubject invention have been presented for purposes of illustration anddescription and for a better understanding of the invention. It is notintended to be exhaustive or to limit the invention to the precise formdisclosed; and obviously many modifications and variations are possiblein light of the above teaching. The particular embodiments were chosenand described in some detail to best explain the principles of theinvention and its practical application to thereby enable others skilledin the relevant art to best utilize the invention in various embodimentsand with various modification as are suited to the particular usecontemplated. It is intended that the invention be defined by the claimsappended hereto.

What is claimed is:
 1. A packaging system for retaining an articletherein, the packaging system comprising: a first flat sheet memberfoldable into a first container portion; a second flat sheet memberfoldable into a second container portion, the second container portionmoveable to a position adjacent the first container portion; a firstopen area within the first container portion; a second open area withinthe second container portion; and retention means for releasablyretaining the article within the first container portion; wherein thefirst open area and the second open area substantially surround thearticle.
 2. The packaging system of claim 1 and further comprising:connecting means for initially releasably connecting the first flatsheet and the second flat sheet.
 3. The packaging system of claim 2wherein the connecting means is a score line.
 4. The packaging system ofclaim 1 wherein the retention means is a stretchable film layer securedto the first sheet member and the second sheet member, the article beingpositionable between the stretchable film layer and the first sheetmember.
 5. The packaging system of claim 1 and further comprising: aflange portion hingedly connected to the first sheet member, the flangeportion movable against the article upon positioning the secondcontainer portion against the first container portion.
 6. The packagingsystem of claim 5 wherein the flange portion supports the article withinthe first container portion.
 7. The packaging system of claim 1 andfurther comprising a portion of the first sheet member and a portion ofthe second sheet member is positioned between the article and the secondopen area.
 8. A packaging system for retaining an article therein, thepackaging system comprising: a flat sheet member having a plurality ofpanel members; wherein the flat sheet member is foldable into a firstcontainer portion and a second container portion, the second containerportion movable against the first container portion with the articlebeing releasably secured within the first container portion.
 9. Thepackaging system of claim 8 and further comprising means for releasablyretaining the article within the first container portion.
 10. Thepackaging system of claim 9 wherein the means are stretchable film layersecured to the flat sheet member, the article being positionable betweenthe stretchable film layer and the flat sheet member.
 11. The packagingsystem of claim 8 and further comprising: a flange portion hingedlyconnected to the flat sheet member, the flange portion movable againstthe article upon positioning the second container portion against thefirst container portion.
 12. The packaging system of claim 11 whereinthe flange portion supports the article within the first containerportion.
 13. A method for retaining an article within a packagingsystem, the method comprising: providing a flat sheet member; releasablysecuring the article to the flat sheet member; folding the sheet memberinto a first container portion and a second container portion, thearticle being secured within the first container portion; and moving thesecond container portion to a position adjacent the first containerportion.
 14. The method of claim 13 and further comprising: providingretention means for retaining the article within the first containerportion.
 15. The method of claim 14 wherein the retention means is astretchable film layer secured to the flat sheet member, the methodfurther comprising positioning the article between the stretchable filmlayer and the flat sheet member.
 16. The method of 13 and furthercomprising: supporting the article within the first container portion.17. The method of claim 16 wherein the article is supported by a flangeportion hingedly connected to the flat sheet member, the flange portionmovable against the article upon moving of the second container portionagainst the first container portion.